The key to medical plastics success in 2016

Some of MPN’s key contributors reveal their predictions for industry trends in 2016

The medical plastic device sector is continually seeking improvements to improve the health and well-being of us all. Developments in materials, design and manufacturing processes are key to the success of the sector. In recent years technology has been a key focus with increased emphasis on wearable and connected devices. The move towards patient self-care and management has had a visible effect on the market such as the drug delivery sector as manufacturers recognise the need to be part of this ‘smart market’.

This is a vibrant market, keen to explore ways of improving its products and the benefits they offer society. Improved manufacturing processes are always a key focal point as of businesses strive to work more efficiently taking advantage of opportunities and market growth.

According to the organisers of this year’s Chinaplas, the global medical products industry has never been more dependent on plastics and rubber suppliers to help its meet today's healthcare needs. The medical applications incorporating polymers are diverse and numerous, including: drug-delivery systems; sophisticated diagnostic imaging equipment; surgical tools; prostheses and life-maintaining implantable devices; pharmaceutical packaging; various disposables such as tubes, infusion bags, catheters, syringes, and also increasingly, interactive healthcare monitoring. The US trade association Advamed, estimates that the medical device industry is currently worth $120 billion globally.

Market share

According to Christoph Lhota, vice president Engel, medical, the market for plastic products for medical technologies will grow slightly in 2016.

“We also see potential in Europe but it is strongest in North America,” he adds.

Lhota says growth is being driven by the diagnostics market including laboratory products and point-of-care applications. In all areas, innovative technologies are preparing the way for new functionalities, more cost-effective production and safer patient care.

He cites four major examples:

·        Medication delivery devices such as inhalers and auto-injectors are becoming increasingly intelligent. Thanks to the integration of electronic functions, they network themselves with other systems in order to ensure the unbroken documentation of therapy-relevant information;

·        In diagnostics, sample vessels are becoming widely used that have functionalised surfaces to either specifically initiate or prevent interaction between the sample and the vessel wall;

·        Barrier functions are at the focus for pharmaceutical packaging. They pave the way for the further substitution of plastics for glass;

·        Innovative, highly integrated processing methods help achieve a more cost-effective production and therefore make high-quality medical products affordable worldwide. For instance, the needles of injection syringes are overmoulded directly in the mould, not only making the production more efficient but also saving raw material.

Keeping it personal

Thomas Kinisky, president and CEO of Saint-Gobain Performance Plastics says: “Looking forward in 2016, Saint-Gobain Performance Plastics (PPL) is expecting to see a few trends influencing medical plastic manufacturing.”

 Kinisky says that firstly we should see an acceleration of cell therapy as it moves on to the development phase.

 “We expect personalised medicine to require a higher volume of engineered and customised plastic disposables in the mid-term, as the commercialisation of treatments gains traction.

 Saint -Gobain PPL is also making strides in regards to quality/regulatory/validation (QRV) requirements. This comes as the use of plastic-based disposables continues to gain share, particularly in bio-processing. The QRV requirements will continue to increase for the manufacturers of the plastics disposables. End-users will have to demonstrate quality across the supply-chain, so suppliers will have to expand their compliance systems.”

Importance of packaging

Eric Resnick, president, pharmaceutical delivery systems, proprietary products, West says that in 2016, many drug manufacturers will focus on the development of large-molecule antibodies for new therapeutics and we will see an increased demand for innovative and effective drug packaging and delivery that can accommodate larger doses given over a longer period of time.

“Additionally, we will see a continued interest in alternatives to glass such as polymer-based systems for drug packaging and delivery systems, especially for biologics, which can be sensitive to glass containers. Since biologics are sensitive drug products, there is a need for ultra-clean packaging components to ensure that there is a low risk of contamination or particulates.

“The connected health movement will drive forward the convergences of digital technologies and drug delivery systems. With that, wearable injector systems for the treatment of chronic conditions will become increasingly popular. This will lead to an increased focus on innovations for new, integrated drug container systems that further aid patient adherence, comfort and safety.

In terms of device manufacturing, 3D printing technology will show its disruptive potential, as many industry players will start working to integrate it into the development and manufacturing processes. This in turn will, however, require additional insights and expertise regarding the material and chemical compounds and processes,” he adds.

Automation of production

"In the medical technology segment, we expect an increase in the automation of production processes through the integration of downstream processing steps in the coming year, 2016. There will also be a focus on the use of high-speed machines for the packaging of pharmaceutical products," explains Sven Kitzlinger, application engineering medical technology at Arburg. "In both cases there are increasing synergies with the packaging department, where we also have a high level of expertise."

One example of the integration of downstream processing steps in a complete turnkey system is the manufacture and packaging of ready-to-use dental drills made from PEEK under cleanroom conditions.

Innovation

Alan Davies, director of home healthcare for the UK and Ireland at Philips is clear in the trends for the sector. He says: “The NHS is currently experiencing an exponential growth in the demand for non-acute care, with estimates citing that by 2030 just under one-in-three in the UK living with a long-term condition. So it’s exciting that 2016 looks likely to bring with it an increasing number of new innovations that seek to directly address these demands.

“From our experiences in the sector, we expect to see more programmes and devices that educate people on health maintenance and these will become increasingly sophisticated to the point of becoming recognised medical devices.”

Davies says that another trend will be innovations that are supported by sophisticated health networks, such as Philips HealthSuite Digital Platform, to facilitate closer collaboration between patients and their care teams.

“For those living with long-term conditions, innovative self-care programmes will offer them tools to better manage their health while remaining independent, by increasing the ease of access to consultations with their health teams from their own home.

“While acute services will always be there to care for the very ill, we expect 2016 to offer more examples of how innovation in this space can help to provide healthcare more holistically, help people maintain good health and support those with long-term conditions to live independently,” he adds.